Terminal, molded product for power module provided with terminal, and method of manufacturing molded product for power module provided with terminal

Abstract

There are provided a method of manufacturing a molded product for a power module capable of integrally molding terminals and a substrate, and a terminal in a particular shape used for the manufacturing method. The method of manufacturing the molded product for a power module includes the steps of: inserting a first tip portion of each of terminals having a particular shape into a substrate; arranging the substrate in a mold such that the second tip portion is inserted into a terminal insertion portion inside the mold; and integrally molding the substrate and the terminals by flowing resin into the mold.

What is claimed is: 
     
       1. A method of manufacturing a molded product for a power module, the method comprising the steps of:
 preparing a terminal and an L-shaped substrate with a first portion and a second portion that is perpendicular to the first portion and has a wiring portion, the L-shaped substrate being in the form of a plate, which is L-shaped in a plane orthogonal to the longitudinal axis of the terminal, the terminal comprising a main body connecting two end portions, a first tip portion including one of the end portions, a second tip portion including an end portion on the opposite side of the first tip portion and a first expanded portion provided on the main body, an area of the first expanded portion being larger than an area of the main body relating to a cross section orthogonal to the longitudinal direction of the main body; 
 inserting the terminal into the L-shaped substrate from the first tip portion; 
 arranging the L-shaped substrate with the terminal in a mold such that the second tip portion is inserted into a terminal insertion portion inside the mold; and 
 integrally molding the L-shaped substrate and the terminal by flowing resin into the mold so that the wiring portion of the second portion of the L-shaped substrate is exposed for connection to another apparatus at a position spaced from a vertical line passing through a longitudinal axis of the terminal. 
 
     
     
       2. The manufacturing method according to  claim 1 , wherein a length from a tip of the second tip portion to the first expanded portion is larger than a depth of the terminal insertion portion of the mold. 
     
     
       3. The manufacturing method according to  claim 1 , wherein a length from a tip of the second tip portion to the first expanded portion is the same as or smaller than a depth of the terminal insertion portion of the mold. 
     
     
       4. The manufacturing method according to  claim 3 , wherein the main body is further provided with a second expanded portion, and a length from the tip of the second tip portion to the second expanded portion is larger than the depth of the terminal insertion portion of the mold. 
     
     
       5. A molded product for a power module comprising:
 a resin case; 
 an L-shaped substrate integrated with the case having a first portion and a second portion that is perpendicular to the first portion and has a wiring portion; and 
 a terminal integrated with the case and connected to the L-shaped substrate, wherein 
 the L-shaped substrate is in the form of a plate, which is L-shaped in a plane orthogonal to the longitudinal axis of the terminal, 
 the terminal comprises a main body connecting two end portions, a first tip portion including one of the end portions, a second tip portion including an end portion on an opposite side of the first tip portion and a first expanded portion provided on the main body, an area of the first expanded portion being larger than an area of the main body relating to a cross section orthogonal to the longitudinal direction of the main body, the second tip portion being exposed from the case, and 
 the wiring portion of the second portion of the L-shaped substrate is exposed for connection to another apparatus at a position spaced from a vertical line passing through a longitudinal axis of the terminal.